"A 10-meter-long U-rib can be cleaned in 10 minutes."
"No more noise and dust!"
"This is the first time we try this cleaning method ......"
China Railway Baobaoqiao, a leading domestic steel girder and steel structure enterprise, the workshop masters are full of praise for the big man in front of them.
The U-rib laser cleaning automated production line independently researched and developed for steel bridges, which is the first to realize production and delivery in China, has filled the blank of related technology in the domestic bridge industry.
At present, the production line is being upgraded at the customer's site, and the synchronized operation from single beam to multi-beam laser can multiply the cleaning efficiency.
Significant advantages, widely used, bridge U-rib use of the status quo
With the development of the world's bridges and the advancement of steel structure technology, large-span bridges are more and more using steel structure. At present, the proportion of steel structure bridges in France, Japan, the United States and other countries are 85%, 41% and 35% respectively. Steel structure bridges in China are mainly used for mega-span bridges, and the proportion of steel structure bridges in highway is increasing year by year. And orthotropic anisotropic plate has been widely used in the construction of steel structure bridges for its advantages of light weight and large bearing capacity.
Orthotropic anisotropic bridge deck panels are mainly composed of steel panels as well as cross beams and longitudinal ribs welded to them, with the cross beams mainly being transverse bulkheads and the longitudinal ribs mainly being U-rib structures. As the U-rib can provide greater torsional stiffness and bending stiffness, it can improve the stress state of the whole bridge deck, so it becomes the most commonly used cross-section form of modern orthotropic bridge deck.
Technical depression, urgent need to renew, U-rib cleaning technology analysis
With the increase of steel bridge span, steel bridge manufacturing puts forward higher requirements on the strength of the material, and also puts forward higher requirements on the bonding performance between the weld and the base material. In order to ensure the welding quality of orthotropic anisotropic plate unit, the U-rib needs to be cleaned in its weld channel area before welding with the panel to remove the floating rust, oxidized skin, paint layer, oil and other adherents on the surface.
In the traditional manual grinding process of U-rib, various electric and pneumatic tools are operated manually to carry out the grinding operation, during which the workpiece needs to be turned over repeatedly, which makes the labor intensity of workers extremely great while the grinding quality is unstable and the operation efficiency is low, meanwhile, the dust and noise generated by the grinding will directly threaten the health of workers.
Traditional U-rib sanding equipment adopts contact mechanical sanding, which inevitably brings mechanical vibration and noise, resulting in unstable sanding effect, easy to damage the workpiece, serious noise pollution, poor equipment stability and many other problems. In addition, the existing traditional U-rib sanding equipment needs manual assistance to locate the U-rib to be sanded area before sanding, and can not be adjusted according to the U-rib shape and size differences, and the scope of application is more limited.
Whether it is manual or mechanical sanding, there is a common problem: the cleanliness is not up to standard.
A bridge of hundreds of thousands of tons needs at least millions of U-rib plate units, which is equivalent to the "skeleton" of the bridge, and the cleaning quality of the U-rib to be welded has a key role in the welding quality of the orthotropic deck plate in the subsequent processing process, and it is also the key factor for the service life, safety, wind and wind resistance of the bridge. It is also an important influencing factor of the bridge's service life, safety, wind and earthquake resistance.
In view of the above problems, laser cleaning automated production line and how to break the U-rib cleaning problems?
Directly hit the pain point, know what you need, U-rib laser cleaning solutions
Combined with the transformation and upgrading of the domestic manufacturing industry and the new blueprint of "double-carbon" development, the laser cleaning automation line not only focuses on creating product "intelligence" manufacturing power, but also focuses on product "green" power, and has become the most popular product for U-rib cleaning of steel panels. It has become the most favored industry solution for U-rib cleaning of steel structure panels.
01、Conform to the international standard bright as new
After the primer and floating rust of U-rib to be welded parts are cleaned by laser without medium, the cleanliness can reach SA3 level of international general rust removal standard, which can restore the original color of metal without producing damage to the base material, and the cleaned U-rib weld channel not only has beautiful appearance, but also has better surface consistency, which can effectively improve the welding quality of orthogonal anisotropic bridge deck panels.
02、Silent and environmentally friendly Reduction of smoke and dust
The maximum suction air volume of the fume purification system of the laser cleaning automated production line is 10,000m³/h, and the cleaning residue can be recovered through the vacuum cleaner, and the capture efficiency of the dust can reach 99.9%. In addition, compared with the traditional manual grinding, mechanical grinding and other cleaning methods, laser cleaning does not produce exhaust gas, noise, customer site production noise has been reduced from the past 120 dB to less than 75 dB, greatly reducing the harm to the human body, but also improve the workshop production environment.
03、One time investment cost-effective
Laser cleaning equipment compared to mechanical cleaning, although the initial investment is large, but low maintenance costs, can save 20% of the labor (1 equipment can be operated by 1 person), reduce energy consumption by 57%, 1 equipment to save more than 500,000 yuan per year.
Market-driven "smart" leading the future
Up to now, the total number of modern bridges in China has exceeded 1 million, and the proportion of steel structure bridges has been rising year by year. The "14th Five-Year Plan and 2035 Vision of Steel Structure Industry" proposes that by the end of 2025, the amount of steel structure in China will reach about 1.4 tons, and the proportion of steel structure buildings in the new construction area will reach more than 15%. The "cleaning + intelligent" equipment will also be in the bridge steel structure, rail transportation, railroad locomotives, construction machinery and other industries to show their hands, opening up a new track of green transformation of the manufacturing industry.
